Underlay structure for increased crown stiffening

ABSTRACT

The present invention is a crown-stiffening underlay structure comprised of a flat strip of elastomeric material reinforced with essentially inextensible cords. The cord-reinforced flat strip is wrapped helically around the green tire carcass prior to blowup into the characteristic toroidal shape of a tire carcass. In one embodiment, the underlay structure is disposed between breakers and the radial ply structure. In another embodiment, the underlay is disposed between the radial ply structure and the innerliner. In another embodiment, the afore described underlay structure has an additional and structurally contiguous beam made of elastomeric material.

TECHNICAL FIELD

[0001] The present invention relates to a pneumatic radial ply tire andto the problem of crown lift-off (upward buckling of the tread) when atire is inflated, underinflated or in the case of runflat tires,uninflated. More specifically, the present invention relates to treadunderlays that serve to stiffen the tread and improve handling behavior,in both non-runflat tires, as well as runflat tires during inflated,underinflated or uninflated operation.

BACKGROUND OF THE INVENTION

[0002] A typical driver can usually feel when the handling of anautomobile or light truck deteriorates when one or more tires(non-runflat as well as runflat tires) is underpressurized orunderinflated. During underpressurized operation, the area of contactbetween the road and the tire tread changes in undesirable ways. Mostspecifically, the central region of the ground-contacting portion of thetread tends to lift off of the ground, or to buckle upwards, therebyreducing the tread's area of contact with the ground, which affectsvehicle handling.

[0003] An additional problem associated with underinflated operation iscyclical flexure of the region of the ground-contacting portion of thetire's crown and sidewalls which, especially during high speedoperation, can lead to heating and to fatigue failure of the tirecomponents and structure such that the result can be crown failure ofthe tire.

[0004] The problem of crown lift-off is especially relevant to thedesign of runflat tires, also known as Extended Mobility Tires (EMTs),which are designed to provide continued operation service whenunderinflated or even when uninflated.

[0005] It is believed that the problem of tread lift-off is alsorelevant to the design of non-EMTs which can also suffer handlingproblems when operating in an underinflated mode, especially duringhigh-speed operation when the problem of flexure and flexure-inducedheating is greatest.

[0006] Therefore the goals of tire design include various structuraldesigns that minimize the upward buckling of the central portion of theground-contacting portion of the tread so as to enhance vehicle handlingin all circumstances including, when the tire is at normal operatingpressure, if the tire loses part of its pneumatic pressure or, in thecase of EMTs, if the tire looses all of its inflated pressure.

[0007] In general, the term “runflat,” when applied to an EMT, meansthat the tire structure alone has sufficient strength to support thevehicle load when the tire is operated in the uninflated condition. Thatis, the sidewall and internal surfaces of the tire do not collapse orbuckle onto themselves in the extreme manner associated withconventional tires that are uninflated. Current EMT design is directedtoward providing rigid sidewalls and crown structures, rather than tothe incorporation of internal supporting structures and devices toprevent the tire from collapsing. However, design consideration is alsooften given to the strengthening of the crown region.

[0008] Thus, among the goals of improving tire design, both of EMTs andnon-EMTs, is that of stiffening the crown region against undesirableflexure during low-pressure or no-pressure operation. Among the ways tostiffen the crown is that of incorporating an underlay beneath thetread, radially inward of the belts and radially outward of the plylayers of the carcass.

[0009] For example, Cluzel, in U.S. Pat. No. 5,996,662, describes a“heavy vehicle” reinforcement “composed of at least two crossed workingplies and at least one ply of circumferential cables arranged above thecarcass ply.”

[0010] Colom, U.S. Pat. No. 6,082,426 describes the incorporation of a“crown reinforcement having at least two working crown plies made ofinextensible cables, crossed from one ply to the other and formingangles of between 10° and 45° with the circumferential direction” and“an additional, axially continuous, ply formed of metallic elementsoriented substantially parallel to the circumferential direction . . .place radially between the working plies” and extending laterally to1.05 times the width of the breaker(s).

[0011] Abe, et al., in U.S. No. 4,506,718, describe an off-road vehicletire having an extra layer of reinforced crown material designed toresist penetration by sharp objects.

[0012] Costa Pereira, et al., in U.S. No. 6,199,612, describe a “singlelayer of cushion compound between the cords of the carcass reinforcementthat are furthest radially outward in the crown and eh cords of thebelting that are furthest radially inward in the crown,” for the purposeof increasing crown rigidity without sacrificing losses to hysteresis;but no reinforcing cords are evident in this design of Pereira, et al.

[0013] Southarewsky, in U.S. No. 5,759,314, shows a crown reinforcementfor a biased ply tire in which the reinforcement consists of “a memberdisposed between a first carcass and an additional carcass in the crownregion of the tire for restricting the circumferential growth of thetire. The reinforcement member includes a plurality of cords oriented atzero degrees.

[0014] The total circumferential strength of the reinforcement member isabout 20% to 250% of the circumferential strength of the carcass plies.”

[0015] A further goal is to minimize the weight of such crownreinforcements, especially given that, because they are disposedradially distant from the axis of rotation, add to the tire's rotationalmoment of inertia about its main axis of rotation, which detracts fromvehicle acceleration due to both the excess weight and the increasedmoment of inertia, as well as heat build up due to flexure of theadditional material. The ideal crown stiffening invention has minimalweight. In EMT tires, the sidewall reinforcements tend to conveyundesirable bending stresses to the crown region during low-pressure andno-pressure operation, which is also to be resisted by the crownreinforcement so as to give improved tire life underless-than-optimal-pressure operation.

[0016] With respect to conventional non-EMT tires, it is believed thatthe benefits of a crown and tread region that is resistant to upwardflexure or liftoff during underinflated operation is, of course,improved vehicle handling during the interval until the tire can bereinflated to full pressure or otherwise repaired and reinflated to fulldesign pressure.

SUMMARY OF THE INVENTION

[0017] The present invention relates to a pneumatic radial ply tirehaving a tread, a carcass with two sidewalls, two inextensible annularbeads, a radial ply structure, a belt structure located between thetread and the radial ply structure, and an air impermeable innerliner.In addition, a crown stiffening underlay structure is disposed radiallyinward of and adjacent the belt structure and radially outward of andadjacent the radial ply structure. The underlay structure is comprisedof a single flat strip of material disposed in a plurality of spacedapart circumferential windings about the tire carcass. The flat strip iscomprised of a plurality of high modulus, essentially inextensible cordsembedded more or less parallel to one another within an elastomericmatrix. The high modulus, essentially inextensible cords are made of amaterial selected from a group of materials exemplified by nylon, rayon,polyester, aramid, metal and glass. The overall lateral width of theunderlay structure is less than the lateral width of the breakerstructure. The plurality of essentially inextensible cords embeddedwithin the elastomeric matrix of the underlay structure may or may notbe cut at regular intervals of between about 10 cm and 20 cm, to enablethe underlay strip to increase in length to accommodate the increase incircumference as the green tire carcass is blown up into a toroidalcarcass shape. The cords are cut if the blow up change in diameter ofthe underlay strip is greater than the limited extensibility of thecord.

[0018] In a second embodiment, the present invention relates to apneumatic radial ply tire having a tread, a carcass with two sidewalls,two inextensible annular beads, a radial ply structure, a belt structurelocated between the tread and the radial ply structure, and an airimpermeable innerliner. The tire has a crown stiffening underlaystructure disposed radially inward of and adjacent the belt structureand radially outward of and adjacent the radial ply structure. Theunderlay structure is comprised of a single flat strip of materialdisposed in a plurality of spaced apart circumferential windings aboutthe tire carcass. The flat strip is comprised of a plurality of highmodulus, essentially inextensible cords embedded more or less parallelto one another within an elastomeric matrix and a beam made ofelastomeric material that is contiguous with the elastomeric matrix inwhich the high modulus essentially inextensible cords are embedded. Thehigh modulus, essentially inextensible cords are made of a materialselected from a group of materials exemplified by nylon, rayon,polyester, aramid, glass and metal. The overall lateral width of theunderlay structure is less than the lateral width of the breakerstructure. The plurality of essentially inextensible cords embeddedwithin the elastomeric material of the underlay structure may or may notbe cut at regular intervals of between about 10 cm and 20 cm in order toenable the underlay strip to accommodate the blown up of the green tirecarcass into the toroidal carcass shape. The cords are cut if the blowup change in diameter of the underlay strip is greater than the limitedextensibility of the cord. The beam is made of elastomeric materialhaving a modulus of elasticity that is equal to or greater than themodulus of elasticity of the elastomeric material within which theessentially inextensible cords are embedded. The beam has a thickness ofbetween about 1 mm and 10 mm and most preferably a thickness of betweenabout 3 mm and 7 mm. The beam portion of the underlay structure ispositioned radially inward of the main body of the underlay structure orradially outward of the main body of the underlay structure.

[0019] In a third embodiment, the present invention relates to apneumatic radial ply tire having a tread, a carcass with two sidewalls,two inextensible annular beads, a radial ply structure, a belt structurelocated between the tread and the radial ply structure, and an airimpermeable innerliner. The tire has a crown stiffening underlaystructure disposed radially inward of and adjacent the radial plystructure and radially outward of and adjacent the innerliner. Theunderlay structure is comprised of a single flat strip of materialdisposed in a plurality of spaced apart, circumferential windings aboutthe tire carcass. The flat strip is comprised of a plurality of highmodulus essentially inextensible cords embedded more or less parallel toone another within an elastomeric matrix. The high modulus essentiallyinextensible cords are made of a material selected from a group ofmaterials exemplified by nylon, rayon, polyester, arimid, metal andglass. The overall lateral width of the underlay structure is less thanthe lateral width of the breaker structure. The plurality of essentiallyinextensible cords embedded within the elastomeric material of theunderlay structure may or may not be cut at regular intervals of betweenabout 10 cm and 20 cm in order to enable the underlay strip toaccommodate the blown up of the green tire carcass into the toroidalcarcass shape. The cords are cut if the blow up change in diameter ofthe underlay strip is greater than the limited extensibility of thecord.

[0020] In another embodiment, the present invention relates to apneumatic radial ply tire having a tread, a carcass with two sidewalls,two inextensible annular beads, a radial ply structure, a belt structurelocated between the tread and the radial ply structure, and an airimpermeable innerliner. The tire has a crown stiffening underlaystructure disposed radially inward of and adjacent the radial plystructure and radially outward of and adjacent the innerliner. Theunderlay structure includes a single flat strip of material disposed ina plurality of spaced apart circumferential windings about the tirecarcass. The flat strip includes a plurality of high modulus essentiallyinextensible cords embedded more or less parallel to one another withinan elastomeric matrix and a beam made of elastomeric material that iscontiguous with the elastomeric matrix in which the high modulusessentially inextensible cords are embedded. The high modulusessentially inextensible cords are made of a material selected from agroup of materials exemplified by nylon, rayon, polyester, aramid, glassand metal. The overall lateral width of the underlay structure is lessthan the lateral width of the breaker structure, and the plurality ofessentially inextensible cords embedded within the elastomeric materialof the underlay structure may or may not be cut at regular intervals ofbetween about 10 cm and 20 cm, most preferably at about 15 cm intervalsin order to enable the underlay strip to accommodate the blown up of thegreen tire carcass into the toroidal carcass shape. The cords are cut ifthe blow up change in diameter of the underlay strip is greater than thelimited extensibility of the cord. The beam is made of elastomericmaterial having a modulus of elasticity that is equal to or greater thanthe modulus of elasticity of the elastomeric material within which theessentially inextensible cords are embedded, and it has a thickness ofbetween about 1 millimeter and 10 mm and most preferably a thickness ofbetween about 3 mm and 7 mm. The beam portion of the underlay structuremight be positioned radially inward of the main body of the underlaystructure, or radially outward of the main body of the underlaystructure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The structure, operation, and advantages of the invention willbecome further apparent upon consideration of the following descriptiontaken in conjunction with the accompanying drawings, wherein:

[0022]FIG. 1 is a cross-sectional view of a prior art EMT designincorporating reinforced sidewalls; FIG. 2A is a cross-sectional view ofan EMT incorporating the present invention;

[0023]FIG. 2B is a cross-sectional detail view of the underlay accordingto the present invention;

[0024]FIG. 3A is a schematic diagram of a deformed tire tread in theregion of the tire's footprint;

[0025]FIG. 3B is a schematic diagram showing the stresses in theupward-bending portion of the tire's footprint;

[0026]FIG. 3C is a schematic diagram showing the stresses in thedownward-bending portion of the tire's footprint;

[0027]FIG. 4A is a schematic view of the underlay according to thepresent invention as applied to an green tire on the building drum wherethe cords have been cut;

[0028]FIG. 4B is a schematic view showing the shape of the underlayaccording to the present invention after the green tire has been blownup into the tread assembly where the cords have been cut;

[0029]FIG. 4C is a schematic view showing the shape of the underlayaccording to the present invention after the green tire has been blownup into the tread assembly where the cords have not been cut;

[0030]FIG. 5 is a cross-sectional view of the underlay according to thepresent invention disposed between the innerliner and the radiallyinwardmost radial ply layer;

[0031]FIG. 6 is a schematic view of the basic underlay invention with anadditional rubber “beam” element; this figure needs to be modified toshow the beam under more than one strip

[0032]FIG. 7A is a cross-sectional view of the underlay with beamaccording to the present invention disposed between the innerliner andthe radially inwardmost radial ply layer, with the beam element locatedradially inward of the cord reinforced flat strip;

[0033]FIG. 7B is a cross-sectional view of the underlay with beamaccording to the present invention disposed between the innerliner andthe radially inwardmost radial ply layer, with the beam element locatedradially outward of the cord reinforced flat strip; and

[0034]FIG. 7C is a schematic diagram showing the tensile and compressivestresses of a bend tire crown, and showing the position of the underlayinvention in relation to the neutral bending axis of the tire crown.

DEFINITIONS

[0035] “Axial” and “axially” means the lines or directions that areparallel to the axis of rotation of the tire.

[0036] “Bead” or “bead core” generally means that part of the tirecomprising an annular tensile member of radially inner beads that areassociated with holding the tire to the rim; the beads being wrapped byply cords and shaped, with or without other reinforcement elements suchas flippers, chippers, apexes or fillers, toe guards and chafers.

[0037] “Belt Structure” or “Reinforcement Belts” means at least twoannular layers or plies of parallel cords, woven or unwoven, underlyingthe tread, unanchored to the bead, and having both left and right cordangles in the range from 17° to 27° relative to the equatorial plane ofthe tire.

[0038] “Breakers” or “tire breakers” means the same as belt or beltstructure or reinforcement belts.

[0039] “Carcass” means the tire structure apart from the belt structure,tread, undertread, over the plies, but including the beads.

[0040] “Circumferential” refers to circular lines or directionsextending along the perimeter of the surface of the tread parallel tothe equatorial direction.

[0041] “Cord” refers to essentially inextensible high modulus fibersmade of single wires or fibers or twisted multiple strands of fibers orwires.

[0042] “Equatorial plane” means the plane perpendicular to the tire'saxis of rotation and passing through the center of its tread; or theplane containing the circumferential centerline of the tread.

[0043] “Footprint” means the contact patch or area of contact of thetire tread with a flat surface at zero speed and under normal load andpressure.

[0044] “Innerliner” means the layer or layers of elastomer or othermaterial that form the inside surface of a tubeless tire and thatcontain the inflating fluid within the tire.

[0045] “Lateral” means a direction parallel to the axial direction, asin across the width of the tread or crown region.

[0046] “Normal Inflation Pressure” means the specific design inflationpressure and load assigned by the appropriate standards organization forthe service condition for the tire.

[0047] “Ply” means a cord-reinforced layer of rubber-coated radiallydeployed or otherwise parallel cords.

[0048] “Radial” and “radially” mean directions radially toward or awayfrom the axis of rotation of the tire.

[0049] “Radial ply structure” means the one or more carcass plies orwhich at least one ply has reinforcing cords oriented at an angle ofbetween 65° and 90° with respect to the equatorial plane of the tire.

[0050] “Radial ply tire” means a belted or circumferentially-restrictedpneumatic tire in which at least one ply has cords which extend frombead to bead are laid at cord angles between 65° and 90° with respect tothe equatorial plane of the tire.

[0051] “Sidewall” means that portion of a tire between the tread and thebead.

[0052] “Tire crown” means the tread, tread shoulders and adjacentportions of the sidewalls.

[0053] “Wedge Insert” means the crescent- or wedge-shaped reinforcementtypically used to reinforce the sidewalls of runflat-type tires.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0054] While the main design goals of a crown reinforcement being thoseof resisting tread liftoff during low-pressure and no-pressureoperation, in both EMTs and non-EMTs, subsidiary goals aresimultaneously to improve vehicle handling and tire durability in normalfully pressurized operation.

[0055] Given those considerations, the present invention relates to acrown-reinforcing or crown-stiffening underlay structure that is lightin weight and includes multiple, spaced apart flat, spiral band windingsof a cord reinforced, elastomeric strip disposed between the ply layersof the carcass and the breaker package beneath the tread or,alternatively, between the innerliner and the radially inwardmost radialply layer.

[0056] In a general sense, there are two basic parts of pneumatic radialply tires used on cars and trucks. One part is the carcass, includingthe plies, two inextensible annular beads, sidewalls, the innerliner,and the elastomeric material, i.e., rubber, which holds those componentstogether after the tire is assembled and the rubber is cured. The otherpart is the crown, which includes the tread and the underlying belts orbreakers, also held together by a matrix of cured rubber. The divisionof the tire into two such parts reflects the manufacturing sequencewherein the crown or tread portion is assembled separately from thecarcass, the latter being assembled on a cylindrical building drumbefore being “blownup” into and joined with the tread/breaker assemblybefore being cured under pressure in a heated press that, as well ascuring the rubber, impresses the tread pattern into the radiallyoutermost rubber and also informs the sidewalls with shape, texture andother patterns.

[0057] In such a generalized or generic tire, the belts or breakers,which are most often made of steel or other essentially inextensiblematerial, are part of the crown assembly and are disposed immediatelyadjacent to, though radially outward of, the ply layers of the carcass.

[0058] An embodiment of the present invention contemplates theinstallation of multiple windings of flat strips of cord-reinforcedelastomer, comprising an underlay structure, disposed in the locationthat is radially inward of the breakers in the crown region and radiallyoutward of the ply layers of the carcass. An alternative embodiment alsocontemplates locating the crown reinforcement of the present inventionin the region that is radially inward of the ply layers and radiallyoutward of the innerliner. Yet another embodiment, contemplates theaddition of an elastomeric “beam” which adds further to the rigidity ofthe aforementioned cord reinforced flat strip.

[0059] The Basic Invention

[0060] Referring now to FIG. 1, there is shown in cross sectional view asegment of a typical, prior art runflat or EMT radial ply tire 100having a tread 114 underlaid by a radially outermost breaker 116 and aninner breaker 118, an outer radial ply layer 120, an inner radial plylayer 122, together comprising a radial ply structure 123, and aninnerliner 124. The tire 100 also has sidewalls 112 a, and 112 b and twoouter sidewall wedge inserts 113 a, and 113 b and two inner sidewallwedge inserts 115 a and 115 b. Though FIG. 1 shows an EMT design, it isalso within the scope of the present invention to incorporate the isintended for its use in EMT as well as non-EMT designs.

[0061]FIG. 2A shows in cross sectional view a segment of a runflat orEMT radial ply tire 200, incorporating an aspect of the presentinvention, having a tread 224 underlaid by a radially outermost breaker226 and an inner breaker 228, together comprising a breaker assembly227. Also shown are an outer radial ply layer 230, an inner radial plylayer 232, an innerliner 234 and sidewalls 233 a and 233 b reinforced byan outer sidewall wedge insert 235 a and 235 b, respectively, and aninner sidewall wedge insert 237 a and 237 b, respectively. Also shown isan underlay structure 238 which is shown in the present embodiment asincluding six circumferential helical windings of underlay strip 240.That is to say, the underlay structure 238 is a single spaced aparthelical winding of a flat strip 240 of material disposedcircumferentially around the tire's carcass in the region radiallyoutward of the carcass plies 230,232 and radially inward of the breakers226,228. The overall lateral width “TW” of the windings of the underlaystrip 240 of the underlay structure 238 is less than the width “bw” ofthe breaker structure 227.

[0062]FIG. 2B is a close-up cross sectional view of one winding of strip240 of the crown stiffening underlay structure 238 (shown in FIG. 1A),according to the present invention. The components of the underlay strip240 are a plurality of high modulus, essentially inextensible cords 242embedded in an elastomeric matrix 244. The underlay strip 240 has awidth “W” of about 6 mm to 20 mm and preferably about 10 mm. Theunderlay strip 240 has a thickness “t” of several millimeters. The cords242 are multi-stranded or single wires or fibers made of materials fromthe class of high modulus materials that includes but it not limited torayon, nylon, polyester, metal, aramid and glass. That is to say, theunderlay structure 238 is comprised of a single flat strip 240 ofmaterial disposed in a plurality of spaced apart, circumferentialwindings about the tire carcass. The flat strip 240 is comprised of aplurality of high modulus essentially inextensible cords 242 embeddedmore or less parallel to one another within the elastomeric matrix 244.

[0063] Principle of Operation

[0064] As stated hereinabove, the design goal of the present inventionis to stiffen the crown and inhibit tread liftoff when a tire, EMT ornon-EMT, is operated at an internal pneumatic pressure that is less thanthe design pressure.

[0065] Referring to FIG. 3A, there is shown schematically, a portion ofthe tread outer circumference 300 of a tire 302 riding upon a roadsurface 304. The view is parallel to the tire's axis, i.e., the view isfrom the side showing more or less the equatorial or central plane ofthe tire 302 in the region where the tread lift will be maximum. Thetire 302 is shown with its footprint deformed due to being filled withless than optimal internal pressure such that the footprint region 306of the tread 300 is deformed upward in the central region mostimmediately adjacent the tire's equatorial plane.

[0066] The upward buckled portion 308 of the tread 300, in the regiondemarcated by the letters “A” and “A′” is shown in detail in FIG. 3Bwhich is a schematic view of the layers extending radially inward fromthe tread 300 to the innerliner 310. The neutral bending axis 312demarcates the separation of the tensile-stressed region 314 from thecompression-stressed region 316. The letters “C” and “T” denote,respectively, compression and tension stresses in the tire components.Since the cords 318 (compare 242) contained within the tread stiffeningunderlay of the present invention lie on the tensile stress side 314 ofthe neutral axis 312, they contribute tensile stresses that add rigidityand resist bending deformation of the tread 300. In FIG. 3B the distance“d” separates the neutral bending axis from the reinforcing cord 318;that separation distance “d” corresponds to being a kind of moment armthrough which the tensile forces acting on the cord 318 work to resistbending of the tire's tread and crown region.

[0067] Regarding the two upward bending regions 320 of the tread 300shown in FIG. 3A, the detail view of FIG. 3C shows the correspondingtensile “T” and compressive “C” stresses in relation to the neutralbending axis 312, above which lie the cords 318 of the underlay of thepresent invention. In this instance, the cords 318 are in compressionbut, being of a high modulus material having the lateral support by anelastomeric matrix 244 (shown in FIG. 2B), the cords 318 are supportedagainst the particular kind of compressive failure known as columnfailure of the sort encountered when long and thin structural membersare subjected to compressive loading along their lengths. The result isthat the reinforcing cords 318 contribute compressive force to resistthe flexure of the crown and tread, thereby stiffening it against treadliftoff. Notice that, as in the tensile case illustrated in FIG. 3B,FIG. 3C shows the same distance “d” separating the neutral bending axisfrom the reinforcing cord 318 and, as in the tensile case above, theseparation distance “d” corresponds to an effective moment arm distancethrough which the compressive forces acting on the cords 318 work toresist bending of the tire's tread and crown region.

[0068] In both the FIGS. 3B and 3C, which show, respectively, downwardand upward bending modes, the presence of the cords 318 contributes toan increase in the bending modulus of the overall structure of the treadregion 300, i.e., making the crown stiffer.

[0069] Installation of the Underlay

[0070] Referring to FIG. 4A, a still to be blown up, green tire carcass400 is shown as it would appear on a building drum (not shown). Theunderlay 402 is comprised on multiple spiral windings 404 (compare 240of the underlay type shown in cross section in FIG. 2B). The number ofspiral windings 404 is in the range of between four and thirty dependentupon the tread band width, most preferably sufficient to cover thecentral two thirds of the tread band width. Small cuts or separations inthe windings 404 at regularly spaced locations 406 may or may not bepresent. While not limited, the cuts are preferably spaced, for example,about 10 to 20 centimeter intervals apart, in the high-modulus cords(compare 242 of FIG. 2B). The cuts or separations at the spacedlocations 406, as shown on the green tire carcass 400, enable theunderlay strip to accommodate the blow up of the green tire carcass intothe toroidal carcass shape 408 as shown in FIG. 4B; the high-moduluscords within the individual windings 404 of the underlay 402 thusaccommodate the blowup process. Cuts are not necessary if the amount ofblowup does not exceed the limit of extensibility of the cords. Thespacing of the cuts 406 in the unblown up tire 400 is such as to allowthe formation of irregularly spaced separations 410 such that theseparations do not overlap laterally across all parts of the windings404 in any arbitrary, laterally oriented, line such as that denoted bythe letters “X-X”. This spacing thereby preserves the underlay's treadstiffening properties more or less uniformly around the circumference ofthe blown up tire carcass 408.

[0071] Referring to FIG. 4C, a blown up, green tire carcass 420 isshown. The underlay 422 is comprised on multiple spiral windings 424(compare 240 of the underlay type shown in cross section in FIG. 2B).The number of spiral windings 424 is in the range of between four andthirty dependent upon the tread band width, most preferably sufficientto cover the central two thirds of the tread band width. The underlaystrip 422 is sufficiently elastic to accommodate the blow up of thegreen tire carcass 420 into the toroidal carcass shape as shown in FIG.4C; the high-modulus cords within the individual windings 424 of theunderlay 422 thus accommodate the blowup process. Cuts, as shown inFIGS. 4A and 4B are not necessary since the amount of blowup does notexceed the limit of extensibility of the cords.

[0072] Second Embodiment

[0073] A second embodiment of the present invention is characterized byits location, namely radially farther inward from the aforementionedlocation between a breaker package 504 and the radial ply layers of atire 500. More specifically, the crown stiffening, cord reinforced flatstrips of elastomeric tread underlay material, as described above, aredisposed radially inward of the innermost radial ply layer and radiallyoutward of the innerliner. FIG. 5 illustrates the second embodimentlocation in a tire 500 having a tread 502, a breaker package 504comprised of a radially outer breaker 506 and a radially inner breaker508. The tire 500 has a breaker package 504, sidewalls 512 a,512 b, anouter ply layer 514, an inner ply layer 516 and an innerliner 518. Thetire segment shown in FIG. 5 is of the EMT design, but the inventorsintend that the present invention find utility within non-EMT designs aswell in substantially the same form shown, but without the sidewallinserts 520 a,520 b and 522 a,522 b, respectively, as shown inconnection with this EMT illustrative example. The windings 524 (compare240 of the underlay of the present invention are shown in FIG. 5)situated between the innerliner 518 and the radially innermost ply layer516.

[0074] A benefit of this radially inward location, as shown in FIG. 5relative to the first embodiment location, is the greater mechanicaladvantage of the underlay in stiffening the crown region and tread. Themechanical advantage becomes evident upon contemplation of FIGS. 3B and3C wherein the distance “d” between the neutral bending axis and thecords 318 that are embedded in the underlay strip increases, which meansthat the moment arm distance, i.e., “d”, between the cord and theneutral bending axis is increased in this second embodiment of thesubject invention; this increase in separation distance “d” between theneutral axis and the reinforcing cord 318 (FIGS. 3B, 3C) becomes greaterby an amount roughly equal to the thickness of the ply layers 514,516,thereby giving an increased effective ‘moment arm distance “d”’ incontributing to the overall bending moment of inertia of the crown andtread region of a tire incorporating this invention.

[0075] Third Embodiment

[0076]FIG. 6 illustrates, in cross sectional view, an embodiment of thepresent invention in which the cord reinforced flat strip 600, which iscomprised of a plurality of reinforcing cords 602 (compare 242) embeddedwithin an elastomeric matrix 604 (compare 244) and an additional rubbercushion 606 called a “beam”, herein, that is contiguous with the othercomponents of the flat strip portion of the invention as describedhereinabove. Note that the beam 606 is disposed under each turn of theflat strip 600. The beam 606 has a thickness “u” and a width “v”, thelatter being less than the width “w” of the cord reinforced flat strip600. The beam 606 has a thickness “u” of between about 1 millimeter and10 millimeters and most preferably a thickness of between about 3 mm and7 mm. The beam 606 is made of elastomeric material having a post-curemodulus of elasticity that is equal to or greater than the modulus ofelasticity of the matrix 604 within which the cords 602 are embedded.

[0077] The beam 606 has the advantage of contributing to the tread andcrown stiffening properties of the present underlay invention by twomethods: (1) because of the intrinsic rigidity of the beam 606, and (2)because of the thickness “u” of the beam in displacing compressive andtensile stress load-bearing portion of the main body of the strip, i.e.,the elastomeric matrix 604 containing the reinforcing cords 602,radially farther outward from the neutral bending axis of thecrown/tread region of the tire, increases yet further the displacementof the underlay, specifically its high-modulus cord components, from theneutral bending axis which thereby contributes yet further to anincrease in the bending moment of inertia of the crown/tread region ofthe tire.

[0078] Beam Beneath the Underlay

[0079]FIGS. 7A and 7B show in cross sectional view two tires 700 and 702which are substantially the same except for the orientation of theunderlays 704 and 706, respectively, according to the present invention.Specifically, the underlays 704 and 706 have their respective beams 708and 710 disposed at different orientations in the respective FIGS. 7Aand 7B. Each of the tires 700 and 702 generally have identicalconstructions (and therefore the use of similar designation numbersbetween FIGS. 7A and 7B refers to substantially the same components)except for the underlays 704 and 706 as previously discussed and asdescribed in more detail hereinafter. The tires 700 and 702 each have atread 712 and a breaker structure 714 comprised of two breakers 715,716,sidewalls 718 a,718 b, a radially outer radial ply 720, a radially innerradial ply 722, and an innerliner 724. In FIG. 7A, the windings of thesix windings of the underlay 704 with beam 708 are oriented such thatthe beam portion 708 (compare 606 in FIG. 6) is radially inward of thecord reinforced elastomeric portion of the underlay 600 shown in FIG. 6.

[0080] In FIG. 7B, the six windings of the underlay 706 with beamportion 710 (compare 606 in FIG. 6) are oriented in such as way that thebeam portion lies radially outward of the cord reinforced elastomerportion of the underlay structure 706.

[0081]FIG. 7C is a schematic view side view (i.e., a view parallel tothe axis of rotation of the tires 700 and 702) of and upward (orradially inward) bent portion of the tread and crown region 730 of thetires 700 and 702, as would be found in the upward buckled portion ofthe tread footprint when the tire is operated at an internal pressurethat is less than optimal to maintain a most desired footprint. Theouter portion of the tire 700, i.e., the tread region 732, and the innerportion of the tire, i.e., innerliner region 734, constitute a structurethat is bent in such as way as to put the radially inward innerlinerside 734 into tension T while the radially outward tread region side 732experiences compression forces C. The two regions of tension T andcompression C are separated by the neutral bending axis 736. In the viewshown in FIG. 7C, the underlay 738 (representing either respectiveunderlays 704 and 706 in FIGS. 7A and 7B) is shown separated from theneutral bending axis 736 by a variable distance “vd”, which is calledvariable because it can be varied for specific tire designs requiringgreater or lesser amounts of crown stiffening. For example, in FIG. 7Awhere the beam portion 708 is disposed radially inward of the main bodyof the cord reinforced elastomeric portion of the underlay 704, theaddition of the beam will cause the distance “vd” to be greater than ifthe beam were not present, i.e., without the beam, the tire would be asdescribed above in reference to FIGS. 3B and 3C. But with the additionof the beam portion 708, the distance “vd” can be increased according tothe thickness “u” (see FIG. 6) of the beam portion and/or in relation tothe elastic modulus of the rubber compound of which the beam portion isformulated. The greater the distance “vd”, the greater will be thebending moment of inertia of the crown region of the tire, for thereasons described hereinabove. Alternatively, the underlay with beam canbe installed such that the beam portion lies radially outward of thecord reinforced elastomeric portion, as shown in FIG. 7B, in which case,the essentially inextensible cords (compare 602 in FIG. 6) will bedisplaced farther from the neutral bending axis 736 by the thickness “u”of the beam 710, thereby increasing the variable distance “vd”, and thusalso contributing an increase to the bending moment of inertia of thetire crown over and above that illustrated in reference to FIGS. 3Athrough 3C.

[0082] Finally, the inventors further envision the deployment of theherein described underlay with beam in the region that is radiallyinward of the ply layers and radially outward of the innerliner (notshown), thereby achieving yet greater increases in crown stiffness, asneeded in various EMT and non-EMT tire designs. In such a location, thebeam portion of the underlay might be, as designs needs require,radially inward or radially outward of the main cord-reinforced flatstrip portion of this underlay invention.

[0083] Road Tests

[0084] Tests of the underlay invention show that vehicle steering isimproved when running straight, and is not degraded in turns.Furthermore, on relatively soft tar macadam roads (which often tend todevelop track ‘grooves’ associated with heavy truck traffic), a car withthese tires that are equipped with the present invention have been shownto be less likely to be affected by the grooves, thereby yieldingimproved tracking.

[0085] Although the invention has been illustrated and described indetail in the drawings and foregoing description, the same is to beconsidered as illustrative and not restrictive in character—it beingunderstood that only preferred embodiments have been shown anddescribed, and that all changes and modifications that come within thespirit of the invention are desired to be protected. Undoubtedly, manyother “variations” on the “themes” set forth hereinabove will occur toone having ordinary skill in the art to which the present invention mostnearly pertains, and such variations are intended to be within the scopeof the invention, as disclosed herein.

What is claimed:
 1. A pneumatic radial ply tire having a tread, acarcass with two sidewalls, two inextensible annular beads, a radial plystructure, a belt structure located between the tread and the radial plystructure, and an air impermeable innerliner, said tire beingcharacterized by: a crown stiffening underlay structure disposedradially inward of and adjacent the belt structure and radially outwardof and adjacent the radial ply structure, the underlay structure beingcomprised of a single flat strip of material disposed in a plurality ofspaced apart circumferential windings about the tire carcass, the flatstrip being comprised of: a plurality of high modulus essentiallyinextensible cords embedded more or less parallel to one another withinan elastomeric matrix.
 2. The tire of claim 1 in which the high modulusessentially inextensible cords are made of a material selected from agroup of materials exemplified by nylon, rayon, polyester, aramid, metaland glass.
 3. The tire of claim 1 in which the overall lateral width ofthe underlay structure is less than the lateral width of the breakerstructure.
 4. The tire of claim 1 in which the plurality of essentiallyinextensible cords embedded within the elastomeric matrix of theunderlay structure are cut at regular intervals of between about 10 cmand 20 cm, most preferably at about 15 cm intervals to enable theunderlay strip to increase in length to accommodate the increase incircumference as the green tire carcass is blown up into a toroidalcarcass shape.
 5. A pneumatic radial ply tire having a tread, a carcasswith two sidewalls, two inextensible annular beads, a radial plystructure, a belt structure located between the tread and the radial plystructure, and an air impermeable innerliner, said tire characterizedby: a crown stiffening underlay structure disposed radially inward ofand adjacent the belt structure and radially outward of and adjacent theradial ply structure, the underlay structure being comprised of a singleflat strip of material disposed in a plurality of spaced apartcircumferential windings about the tire carcass, the flat strip beingcomprised of: a plurality of high modulus essentially inextensible cordsembedded more or less parallel to one another within an elastomericmatrix; and a beam made of elastomeric material that is contiguous withthe elastomeric matrix in which the high modulus essentiallyinextensible cords are embedded.
 6. The tire of claim 5 in which thehigh modulus essentially inextensible cords are made of a materialselected from a group of materials exemplified by nylon, rayon,polyester, aramid, glass and metal.
 7. The tire of claim 5 in which theoverall lateral width of the underlay structure is less than the lateralwidth of the breaker structure.
 8. The tire of claim 5 in which theplurality of essentially inextensible cords embedded within theelastomeric material of the underlay structure are cut at regularintervals of between about 10 cm and 20 cm, most preferably at about 15cm intervals in order to enable the underlay strip to accommodate theblown up of the green tire carcass into the toroidal carcass shape. 9.The tire of claim 5 in which the beam is made of elastomeric materialhaving a modulus of elasticity that is equal to or greater than themodulus of elasticity of the elastomeric material within which theessentially inextensible cords are embedded.
 10. The tire of claim 5 inwhich the beam has a thickness of between about 1 mm and 10 mm and mostpreferably a thickness of between about 3 mm and 7 mm.
 11. The tire ofclaim 5 in which the beam portion of the underlay structure ispositioned radially inward of the main body of the underlay structure.12. The tire of claim 5 in which the beam portion of the underlaystructure is positioned radially outward of the main body of theunderlay structure.
 13. A pneumatic radial ply tire having a tread, acarcass with two sidewalls, two inextensible annular beads, a radial plystructure, a belt structure located between the tread and the radial plystructure, and an air impermeable innerliner, said tire characterizedby: a crown stiffening underlay structure disposed radially inward ofand adjacent the radial ply structure and radially outward of andadjacent the innerliner, the underlay structure being comprised of asingle flat strip of material disposed in a plurality of spaced apartcircumferential windings about the tire carcass, the flat strip beingcomprised of: a plurality of high modulus essentially inextensible cordsembedded more or less parallel to one another within an elastomericmatrix.
 14. The tire of claim 13 in which the high modulus essentiallyinextensible cords are made of a material selected from a group ofmaterials exemplified by nylon, rayon, polyester, aramid, glass andmetal.
 15. The tire of claim 13 in which the overall lateral width ofthe underlay structure is less than the lateral width of the breakerstructure.
 16. The tire of claim 13 in which the plurality ofessentially inextensible cords embedded within the elastomeric materialof the underlay structure are cut at regular intervals of between about10 cm and 20 cm, most preferably at about 15 cm intervals in order toenable the underlay strip to accommodate the blown up of the green tirecarcass into the toroidal carcass shape.
 17. A pneumatic radial ply tirehaving a tread, a carcass with two sidewalls, two inextensible annularbeads, a radial ply structure, a belt structure located between thetread and the radial ply structure, and an air impermeable innerliner,said tire characterized by: a crown stiffening underlay structuredisposed radially inward of and adjacent the radial ply structure andradially outward of and adjacent the innerliner, the underlay structurebeing comprised of a single flat strip of material disposed in aplurality of spaced apart circumferential windings about the tirecarcass, the flat strip being comprised of: a plurality of high modulusessentially inextensible cords embedded more or less parallel to oneanother within an elastomeric matrix; and a beam made of elastomericmaterial that is contiguous with the elastomeric matrix in which thehigh modulus essentially inextensible cords are embedded.
 18. The tireof claim 17 in which the high modulus essentially inextensible cords aremade of a material selected from a group of materials exemplified bynylon, rayon, polyester, aramid, glass and metal.
 19. The tire of claim17 in which the overall lateral width of the underlay structure is lessthan the lateral width of the breaker structure.
 20. The tire of claim17 in which the plurality of essentially inextensible cords embeddedwithin the elastomeric material of the underlay structure are cut atregular intervals of between about 10 cm and 20 cm, most preferably atabout 15 cm intervals in order to enable the underlay strip toaccommodate the blown up of the green tire carcass into the toroidalcarcass shape.